Methods of using a 4-way compression grooved coupling

ABSTRACT

A method for joining and sealing two grooved-ended pipe segments without disassembling a coupling is disclosed. The coupling has a housing with upper and lower arcuate housing segments and left and right bridge segments. Each bridge segment has at least one set of dihedrally angled faces that engage corresponding faces each in the upper and lower housing segments. Drawing the upper and lower segments inwardly together along a first axis, presses each bridge segment inward along a second axis roughly tangential to the first axis. All segments are loosely pre-assembled into a coupling which has a one-piece circular sealing gasket that has an inward circumferential and centrally positioned pipe stop that has an inner diameter smaller than an outer diameter of the pipes to be joined.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional of pending U.S. non-provisional patent applicationSer. No. 12/955,891, filed Nov. 29, 2010, and also claims priority toU.S. provisional patent application Ser. No. 61/265,327, filed Nov. 30,2009, the entirety of which applications are incorporated by referenceherein.

FIELD

The invention relates to pipe joints; more particularly, it relates tohousing type pipe couplings for creating a sealed connection betweencoaxial groove ended pipes.

BACKGROUND

Housing type pipe couplings are widely used for axially joining twopipes together in such a way as to create a non-leaking union betweenthe pipe ends. To prevent leakage, it is often desirable to preventlongitudinal, angular or rotational movement of the pipe ends within thecoupling. This type of coupling is called a rigid coupling

Generally, the coupling is formed of arcuate housing segments which arefastened around the pipe ends to form a generally ring-like couplinghousing. Typically, two segments are used, a pair of arcuate orgenerally semicircular housing halves, which are fastened together,often bolted together. Housing halves are substantially U- or C-shapedin longitudinal (axial) cross section to provide room for gasket pieces.In some models, the inwardly projecting peripheral edges of the housinghalves, also referred to as shoulders, are shaped with keys or lands forinterlocking within circumferential grooves now commonly provided in thepipe ends.

The coupling is secured as bolts are tightened through bolt holes untilthe key segments engage the circumferential grooves on the pipe ends,thus fastening the pipes together. Where the two housing halves meetaround the circumference of the pipes, a mating structure is often usedto lock one housing half to the other and to add stability. A rubbergasket, also frequently U-shaped or C-shaped in longitudinal (axial)cross-section, is typically arranged within the coupling in a gasketpocket formed by the U-shaped longitudinal cross section of the couplinghousing, such that when the housing halves are tightened against thepipe ends the inner peripheral edges of the gasket are sealed againstthe pipe end portions.

Pipe ends are typically grooved using either a rolled or cut groove. Aroll groove uses a rolling machine to displace the pipe walls forming acurved-edged groove containing a top corner and a bottom corner with thetop corner to corner separation longer than the bottom corner to cornerseparation. The gasket sealing surface is the distance between the outergroove wall and the end of the pipe. A cut groove removes pipe materialto form a groove with straight walls perpendicular to the longitudinalaxis of the pipe and therefore has no rounded corners.

Whether rolled or cut, the groove manufacturing method must accommodatesignificant tolerances set by the AWWA C-606 for gasket sealing surface,groove width, groove diameter, and outer diameter. Any pipe couplingmust also accommodate such dimensional variations.

Several designs are in use which attempt to minimize longitudinal,angular or rotational movement of the pipe ends within the coupling.Angled self-adjusting couplings and tongue and groove style rigidcouplings have slightly oval variable internal circumferential diametersthat shrink when a coupling is tightened until it grips the pipe endseliminating angular movement caused by variable outer diameters andgroove depths. However, as key width is smaller than groove width tofacilitate easy installation within tolerances, space between the keyand corresponding groove allows for some longitudinal movement whenpipes are exposed to pressure thrusts or thermal movement. Through thesedesigns, longitudinal movement is effectively reduced, but nevercompletely eliminated.

It is believed that conventional or known ‘pre-assembled’ couplingdesigns have not taken hold in the industry because they appear torequire complex in situ assembly. For many years, in situ assembly andinstallation of such couplings has been the rule because no betteralternative appeared to be practical, and manufacturers were offeringsingle piece round gaskets that purportedly stretched to fit the pipe athand, or else were using multi-part gasket pieces. For instance oneknown pre-assembled coupling, using a single piece gasket, hasadvertised that assembly would be simple and easy, even in hard to reachplaces, because the gasket would purportedly stretch to accommodate theinserted pipe until it could be locked in and sealed by tightening thecoupling's bolts. However, market research suggests that this design hasnot acquired a large following, and laboratory tests have shown what isbelieved to be an unacceptable seal failure rate, due either toincomplete or inconsistent assembly efforts on site, or to actual tearsor cuts in the gasket itself believed to have been caused by the verydifficult pipe insertion conditions, often requiring wild gyrations ofthe pipe and or the gasket to get them to come together at all.

Other conventional couplings are multi-part disassembled pipe couplingcomponents that must be assembled on site, and in situ, typicallyoverhead and in hard to reach places. These couplings use some kind ofseparate member either inside the upper and lower housing halves, orintermediate to the upper and lower housing halves, and typicallyintegral with some kind of sealing material, in a reported attempt toapply some kind of four-way pressure to the pipe sealing material.Typically these separate members are fitted in grooves or channelsprovided in upper and lower arcuate housing halves. None of thesepreviously disclosed couplings appear to be in current use, and there isreason to believe that none of them was ever effective at rigidlyjoining and sealing two pipe segments together. It is also believed thatnone of them actually deliver real four-way compression either verywell, or very consistently.

None of these couplings use a one-piece sealing gasket, and none of themcan be installed onto respective pipe ends without first beingdisassembled. Also none of the couplings have slidably engaging dihedralangular faces where bridge segments engage corresponding upper and lowerhousing segment faces, such that all four segments move towards thecenter of the coupling as the bolts and nuts are tightened.

Housing type mechanical couplings on grooved-end pipes usually have twohousing segments, some kind of rubber gasket and two pairs of bolts andnuts as shown in FIG. 1. When a coupling is installed on a pipe, it mustbe done in components, or a preassembled coupling unit must be brokendown into those components. Then, if the sealing gasket is conventionalone-piece gasket having an inner diameter smaller than the pipe it isdesigned to fit (see FIG. 2), it must be stretched and mounted it ontothe pipe ends. Finally the two housing halves are placed on the gasket,bolts and nuts inserted, and the nuts fastened tight.

When a large number of such couplings are to be installed, higher workefficiency is required to shorten work time and to reduce installationcosts. So assembly on site and gasket stretching, both time consumingand sometimes very difficult depending on conditions and location ofjoint, are inefficient and can become quite expensive.

What is needed, in order to raise efficiency of installation work, is anew type coupling to solve those technical problems, while at the sametime still effectively eliminating longitudinal, angular and rotationalmovement of the pipe ends within the coupling housing.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended asan aid in determining the scope of the claimed subject matter.

A housing type mechanical coupling is disclosed. The coupling isinstalled onto respective pipe ends without first being disassembled.Such a coupling supplied direct from the factory in a pre-assembledconfiguration, all parts in place for installation, with only the nutsloose and ready for tightening, while still providing sufficientcompression on the gasket to secure a leak-tight joint.

The rubber gasket used for the disclosed coupling preferably has aninner diameter (ID) B slightly larger than the pipe outer diameter (OD)and also has an inwardly protruding elastomeric ridge or pipe stop inthe center as shown in FIG. 3. Each respective pipe end thus abuts thisprotrusion and stops there when it is inserted with a preselectedadvantageous insertion depth.

Rubber gaskets for conventional couplings, whether one piece or multiplepieces, are designed with their ID B to be smaller than the pipe OD, asshown in FIG. 2. This is done for reasons of supposed relatively highersealing capability. If gasket ID B is actually slightly larger than thepipe OD as shown in FIG. 3, the gasket can easily be mounted onto thepipe ends, or the pipe ends inserted easily into the gasket, butpreviously this was thought to reduce sealing capability.

To provide relatively uniform compression all around the pipe joint andthus optimize gasket sealing capacity, the disclosed coupling desirablyhas four housing segments as shown in FIG. 4. There are upper and lowerhousing segments, and two bridges. In preferred embodiments, such asthat shown in FIG. 5, the bridges have dihedral angular faces thatslidably engage corresponding upper and lower housing segment faces,such that all four segments move inwards towards the center of thecoupling as the bolts and nuts are tightened.

In preferred embodiments, pipe coupling housing parts have axiallyinwardly projecting lands that mate with the end grooves in the pipes tobe joined. FIG. 6 illustrates an embodiment of the disclosed coupling ina factory assembled form, with loose bolts and nuts, so that it can beinstalled directly onto the pipe without breaking it down into itscomponents. After inserting pipe ends from both sides of the coupling,leak-proof installation is completed quickly and simply by fastening thenuts tight.

A pre-assembled pipe coupling for joining and sealing two grooved-endedpipe segments, without disassembling the coupling, is disclosed. Thisallows for more rapid assembly of pipe systems with more secure and morerigid pipe connections than previously possible. It also makes possiblepipe system assembly in awkward, hard to reach locations, and iteliminates any risk of dropping parts during assembly, thus also savingsystem assembly time, and producing more uniform and consistent assemblyresults.

Each pre-assembled pipe coupling has a housing that includes upper andlower arcuate housing segments and left and right bridge segments. Thesebridge segments are disposed between the upper and lower segments. Eachbridge segment has at least one set of dihedrally angled faces thatengage corresponding faces each in the upper and lower housing segments.A simple embodiment of a bridge segment has two dihedral faces or planesintersecting one another at an angle that is advantageously between 75and 105 degrees, and preferably about 90 degrees. Each of these twofaces, say, for discussion, an upper bridge face and a lower bridgeface, has a corresponding face in its respective upper or lower housingsegment. Corresponding in this sense means roughly the same shape andarea and also disposed at complimentary angles, as will be appreciatedby those skilled in the art. Thus, drawing the upper and lower segmentsinwardly together along a first axis, such as by tightening the bolts ofthe coupling, creates a force along the intersection of thecorresponding segment faces that, because of the angles, presses eachbridge segment inward along a second axis roughly tangential to thefirst axis. It is believed that this four-way compression thus providedexerts a relatively and roughly uniform circumferential force around thecoupling that rigidly joins and seals the two pipe segments.

All segments are desirably loosely pre-assembled with bolts and nutsinto a coupling and all segments preferably each having radiallyinwardly projecting lands that mate with the end grooves in the pipes tobe joined for more secure coupling.

Inside the pre-assembled housing there is a one-piece circularelastomeric sealing gasket. The gasket advantageously has an inwardcircumferential and centrally positioned elastomeric pipe stop, and thispipe stop has an inner diameter smaller than an outer diameter of thepipes to be joined, such that when pipe ends are inserted into eachopening of the gasket, the pipe ends do not touch each other, but arestopped by and separated by the pipe stop.

The gasket has two circumferential sealing lips axially outward from thepipe stop, and each sealing lip has an inner diameter larger than theouter diameter of the pipe segments to be joined, so that pipe ends canreadily and easily be inserted into the gasket with stretching thegasket either before or during insertion of the pipes, and without riskof tearing or dropping the gasket. When speaking of inner diameter forthese sealing lips, the inner diameter is measured at the base of thelip, not the inner tip of the lip. The tips of these sealing lips areelastic and flexible and they do make contact with the pipe end, and arereadily pushed inward to slide along the pipe as it is inserted, thusforming an excellent seal. The gasket body itself however does notstretch, because the pipe OD is smaller than the inner diameter of thegasket body, the pipe OD being roughly just smaller than the diameter ofthe gasket as measured at the base of the sealing lip.

The pre-assembled coupling is thus adapted to readily receive a groovedpipe end into each of both open ends of the coupling, with the two pipeends thereby seated and sealed in the sealing gasket and separated onlyby the gasket pipe stop. Advantageously, the pipe stop has an innerdiameter that is about the same as the inner diameter of the pipes to bejoined, since any lesser pipe stop inner diameter will allow some pipestop to protrude into the flow of whatever is passing through the pipes,while any greater inner diameter provides less and less of a resilientstop for the insertion of the pipes into the gasket and less sealbetween the pipes.

In some embodiments, each bridge segment has a second set of planarfaces that engage second corresponding planar faces each in the upperand lower housing segments. This second set of bridge faces is generallycontiguous with the first set of faces. By contiguous we mean eachsecond face has at least one line of intersection with a first face.Advantageously, these second face sets, or at least planar extensions ofthese second faces, each also meet at their own dihedral angle. Whenthis is the case the angle of the second set of bridge faces isdesirably between 75 and 115 degrees and preferably about 100 degrees.However, these second face sets do not have to be dihedrals in their ownright, but may be more complex spatially angled planes. It is believedthat second sets of bridge faces provide some desirable alignment ofbridge segments with upper and lower segments during final tightening ofthe coupling around the pipe joint.

Some coupling embodiments do not require an inward circumferential andcentrally positioned pipe stop in the gasket, and some embodiments donot require lands in the bridge segments.

A method is disclosed for joining and sealing two grooved-ended pipesegments with a pre-assembled pipe coupling, without disassembling thecoupling. A grooved pipe end from each pipe segment is inserted intoeach of both open ends of a pre-assembled pipe coupling that has aone-piece circular sealing gasket with two circumferential sealing lipsaxially outward from an axial center of the gasket. Each sealing lip hasan inner diameter larger than the outer diameter of the pipe segments tobe joined. Then roughly uniformly compression force is applied aroundthe circumference of the coupling to rigidly join and seal the pipesegments. The roughly uniform compression force around the circumferenceof the coupling is advantageously provided by applying a four-waycompression force to the coupling, such as by the four-way couplingdescribed above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a one embodiment; FIG. 1 is a front elevation of aconventional assembled pipe coupling.

FIG. 2 is a schematic partial section of a conventional pipe gasket.

FIG. 3 is a schematic partial section of the disclosed pipe coupling.

FIGS. 4a-e are front elevations of disclosed assembled pipe couplings.

FIGS. 5a-d are schematic perspective and partial sections of disclosedpipe couplings.

FIG. 6 is a front elevation of a disclosed pre-assembled pipe coupling.

FIG. 7 is an exploded perspective of a disclosed pipe coupling.

FIGS. 8a-c are side, plan and detail views of disclosed coupling bridgepieces.

DETAILED DESCRIPTION

The present embodiments will now be described more fully hereinafterwith reference to the accompanying drawings, in which some embodimentsare shown. The subject matter of the present disclosure, however, may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein. Rather, these embodiments areprovided so that this disclosure will be thorough and complete, and willfully convey the scope of the subject matter to those skilled in theart. In the drawings, like numbers refer to like elements throughout.

Turning now to the drawings, the invention will be described in apreferred embodiment by reference to the numerals of the drawing figureswherein like numbers indicate like parts.

FIGS. 1 and 2 illustrate typical features of some conventional pipecouplings. Coupling 10 has upper and lower arcuate segments 1 and 2,both enclosing gasket 3, and fastened together by bolts 5 and nuts 4.Pipe 20 fitted with end grooves 22 is shown for comparison of diameterswith gasket 3. Conventional pipe gasket 3, especially if provided as aone-piece gasket, has an inner diameter B that is less than the outerdiameter OD of pipe 20. This has been reported to optimize sealing ofgasket 3 on pipe 20. The problem is that gasket 3 must first bestretched onto the end of pipe 20, with attendant effort and risk oftearing or gouging or dropping gasket 3, and with potentialinsurmountable difficulty when at least one pipe end is already in ahard to reach location.

FIG. 3 shows an unconventional comparison of diameters with pipes 20 andgasket 110 inside of pipe coupling 100. Gasket 110 has an inner diameterB (measured at or near the base of sealing lips 112, not at the tips ofthe lips) that is greater than the outer diameter OD of pipe 20 tooptimize quick insertion and quick fit of pipe 20 into gasket 110,without any sacrifice of sealing effectiveness. Abutment of pipes 20with pipe stop 113 inside gasket 110 is schematically illustrated aswell. FIG. 3 schematically illustrates the pipe insertion phase of theprocess, with coupling lands 122 not yet engaged or mated with pipe endgrooves 22. That happens during the coupling tightening phase. (Seegenerally FIGS. 5a-5e .)

FIG. 4 illustrates disclosed variants of a novel pre-assembled pipecoupling. Each alternative embodiment differs principally from theothers only in design and placement of the various bridge segments121-125. In general each coupling 100 has upper housing segment 101,lower housing segment 102, fastened (in FIG. 4a -FIG. 4e is not yetfastened or locked, but rather in pre-assembled state) with bolts 105and nuts 104. Both bridge segments 121 are shown driven fully inward bythe tightening action of the bolts compressing upper and lower segments101, 102 together, such that all four segments are fully and roughlyequally providing circumferential pressure to gasket 110 and to thepipes (not shown in FIG. 4).

FIGS. 5a-5e illustrate, among other details, the four way compressingaction provided by the combination of upper and lower housing segmentsand bridge segments 121 between them. After pipes 20 are inserted intocoupling 100 (FIG. 5b ), with pipe ends abutting and stopped by pipestop 113 of gasket 110, and sealing lips 112 flexed inward and sealingagainst the pipe OD, segment lands 122 are not yet engaged in pipegrooves 22.

In FIG. 5a , when the bolts are tightened, a compressive force isgenerated generally along axis 33, which in turn, because of thecomplementary angular faces 126, 127 of bridge segments with theircorresponding upper and lower segment faces (see, e.g., segment face 107in FIG. 7), drives bridge segments 121 generally inward along axis 32,believed to be at least roughly tangential to axis 33.

In FIGS. 5c-d , bolts are fully tightened, there is generally no gap nowbetween upper and lower housing segments (as there is in FIG. 5a ), andbridge segments 121 are fully driven inward along axis 32 to compressagainst the gasket and the pipe. Coupling lands 122 are now fullyengaged in pipe grooves 22.

FIGS. 6 & 7 show an embodiment of the disclosed pre-assembled couplingin both pre-assembled and exploded perspective views. Schematically,pipe 20 is shown inserted into coupling 100 in FIG. 6. Bolts and nutsare loose and coupling 100 is uncompressed and bridge segments 121 havenot yet been driven in.

FIG. 7's exploded view of the uncompressed but pre-assembled coupling100 affords a more detailed view of aspects of bridge segments 121, asdoes FIG. 8. In perspective, dihedral faces 126, and second face set 127can be better seen, as can be corresponding segment face 107 in lowersegment 102 set at an angle complementary to the lower face 127 ofsegment 121. A segment face corresponding to face 126 and set atcomplementary angle to face 126 is not illustrated, but it is believedthose skilled in the art will appreciate already where such a face willlie, given the rest of this disclosure.

FIGS. 8a-b illustrate details of disclosed coupling bridge segments 121in side and plan views respectively. Bridge segments 121 operate andfunction as described in more detail above with reference to upper 101and lower 102 coupling housing segments, particularly with respect toapplying nearly uniform circumferential radially inward pressure to thejoined pipe segments 20, or at least 4-way inward pressure to the pipejoint. Each bridge segment 121 desirably has a pair of lands 122 formating with and applying pressure to corresponding end grooves 22 inpipe segments 20. When present, lands 122 on bridges 121 have a geometrysimilar to or at least complementary to the geometry of lands 122 on thehousing segments 101, 102.

Bridge 121 has at least one dihedral set of faces 126. This face set 126is comprised of two planar faces disposed to one another at dihedralangle A. In preferred embodiments this angle A is about 90 degrees. Itcan also be exactly 90 degrees, or can vary with good function fromabout 75 to 105 degrees. In FIG. 8b the dotted circular phantom lineschematically illustrates the position of bolt 105 when bridge 121 isassembled into coupling 100. It can be seen that much of face set 126can be cut away, such as illustrated by the cut-away for bolt 105 or byfaces 128, and still properly function. In preferred embodiments, thereare additional face sets 127, which may or may not be dihedral facesets, depending on the relationship between angle A and angle C. For thecase A=C, faces 127 are also simple dihedral faces. If angle C does notequal angle A, then faces 127 form a more complex spatial planar anglewith each other. Preferred embodiments have values for C that are closeto or identical to A. Also, in preferred embodiments, faces 127 are notco-planar with faces 126 (though that is an option in the case A=C) butare instead, with respect to faces 126, swept back from faces 126 atdihedral angle D (detail FIG. 8c ).

In compliance with the statute, the invention has been described inlanguage more or less specific as to structural features. It is to beunderstood, however, that the invention is not limited to the specificfeatures shown, since the means and construction shown comprisepreferred forms of putting the invention into effect. The invention is,therefore, claimed in any of its forms or modifications within thelegitimate and valid scope of the appended claims, appropriatelyinterpreted in accordance with the doctrine of equivalents.

The present disclosure is not to be limited in scope by the specificembodiments described herein. Indeed, other various embodiments of andmodifications to the present disclosure, in addition to those describedherein, will be apparent to those of ordinary skill in the art from theforegoing description and accompanying drawings. Thus, such otherembodiments and modifications are in the tended to fall within the scopeof the present disclosure. Furthermore, although the present disclosurehas been described herein in the context of a particular implementationin a particular environment for a particular purpose, those of ordinaryskill in the art will recognize that its usefulness is not limitedthereto and that the present disclosure may be beneficially implementedin any number of environments for any number of purposes. Thus, theclaims set forth below should be construed in view of the full breadthand spirit of the present disclosure as described herein.

What is claimed is:
 1. A method for joining and sealing twogrooved-ended pipe segments with a pre-assembled pipe coupling withoutdisassembling the coupling, the method comprising: inserting a groovedpipe end from each pipe segment into each of both open ends of apre-assembled pipe coupling having a sealing gasket disposed therein;and applying a four-way compression force around the circumference ofthe pre-assembled pipe coupling to rigidly join and seal the pipesegments by tightening upper and lower arcuate housing segments of thepre-assembled pipe coupling together along a first axis, such tighteningcausing the upper and lower arcuate housing segments to bear upon firstand second sets of dihedrally angled faces of respective left and rightbridge segments, wherein the first set of dihedrally angled faces have aline of intersection with the second set of dihedrally angled faces, thedihedrally angled faces engage corresponding faces each in the upper andlower arcuate housing segments and the left and right bridge segmentsare disposed between the upper and lower arcuate housing segmentswhereby the left and right bridge segments are forced toward one anotheralong a second axis roughly perpendicular to the first axis; wherein allsegments are loosely pre-assembled with bolts and nuts into thepre-assembled pipe coupling and all segments have radially inwardlyprojecting lands that mate with end grooves in the grooved-ended pipesegments.
 2. The method of claim 1, further comprising providing thesealing gasket with an inward circumferential and centrally positionedpipe stop having an inner diameter smaller than an outer diameter of thepipes to be joined, and wherein inserting the grooved pipe end from eachsaid pipe segment into each of said open ends of the pre-assembled pipecoupling comprises seating the two pipe ends in the sealing gasket suchthat the grooved pipe end of the pipe segments are separated only by thepipe stop.
 3. The method of claim 2, further comprising providing thepipe stop with an inner diameter that is the same as an inner diameterof the pipes to be joined.
 4. The method of claim 1, further comprisingproviding the first set of dihedrally angled faces with an angle that isbetween 75 and 105 degrees.
 5. The method of claim 4, further comprisingproviding the first set of dihedrally angled faces with an angle ofabout 90 degrees.
 6. The method of claim 1, further comprising providingthe second set of dihedrally angled faces with a dihedral angle withrespect to the first set of dihedrally angled faces.
 7. The method ofclaim 1, further comprising providing the second set of dihedrallyangled faces with an angle that is the same as the angle of the firstset of dihedrally angled faces.
 8. The method of claim 1, furthercomprising providing the second set of dihedrally angled faces with anangle that is between 75 and 115 degrees.
 9. The method of claim 8,further comprising providing the second set of dihedrally angled faceswith an angle of about 100 degrees.